Facility for processing steel

ABSTRACT

Facilities for processing steel. One facility includes a line for producing packages; a plurality of stackable cassettes for receiving packages; a splitter subfacility; automated transfer apparatus; and an automated overhead crane. The line may be a slitting line with the packages being coils of steel, or a cut-to-length line with the packages being stacks of steel sheets. A premises of the facility comprises a loading area in which packages from the line are loaded into cassettes, a storage area in which cassettes are stored, and a transition zone including at least one transfer position. The automated transfer apparatus moves packages and/or cassettes between the transfer position and the splitter subfacility. The automated overhead crane moves cassettes between the storage area, the loading area, and the transition zone.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Application No.62/635,850, filed Feb. 27, 2018, entitled “FACILITY FOR PROCESSINGSTEEL,” the entire disclosure of which is hereby incorporated herein bythis reference.

BACKGROUND OF THE INVENTION Field of Invention

The invention relates to the field of steel processing.

Background

Coiled steel is ubiquitously produced by steel mills around the world.These coils are often shipped to secondary processors at which variousmachines are situated.

A decoiler turns a coil of steel into a long ribbon of steel having thesame width as the coil.

A slitter turns a long ribbon of steel into two or more narrow ribbonshaving the same length as the long ribbon.

A cut-to-length line turns a long ribbon of steel into a plurality ofsheets of steel, each having the same width as the ribbon.

A coiler turns a long ribbon of steel into a coil having the same widthas the ribbon.

Secondary processors serve a wide variety of customers with equallyvaried needs for product. To meet these needs, processors conventionallyproduce product as needed. Thus, if a customer has a need for a coil ofa certain width and length, the processor draws a coil from inventorythat can be cut and slit to that length and passes it through themachines to produce the coil. Similarly, if a customer has a need forsheets of steel of a certain width and length, the processor draws acoil from inventory that can be cut and slit into sheets of those widthsand lengths and passes it through the machines as required.

At the end of each of the above process, the remaining material iscoiled and returned to inventory using a manual overhead crane.

Coils are conventionally placed in a single layer in a storage area andstabilized against rolling movement.

Attention is given to the coil selected for slitting andcutting-to-length, with a view to minimizing, inter alia, materialwaste.

SUMMARY OF THE INVENTION

Forming one aspect of the invention is a facility comprising: a line, aplurality of stackable cassettes, premises, a splitter subfacility,automated transfer apparatus; and an automated overhead crane.

The line is for producing packages, the line being selected fromslitting line and cut-to-length line, the packages being coils of steelwhen the line is the slitting line and being stacks of steel sheets whenthe line is the cut-to-length line.

In the plurality of stackable cassettes, each cassette is adapted toreceive at least one package.

The premises include: a loading area for loading cassettes withpackages; a storage area in which cassettes are stored; and a transitionzone including at least one transfer position.

The splitter subfacility is for: receiving the contents of a cassette,removing and packaging for shipment at least some of such contents andreturning the remainder; or receiving a cassette, removing and packagingfor shipment at least some of such contents and returning the cassette.

The automated transfer apparatus for moving: the contents of a cassettedisposed at the transfer position to the splitter subfacility and formoving a package from the splitter subfacility to a cassette in thetransfer position; or for moving a cassette in the transfer position tothe splitter subfacility and for moving a cassette from the splittersubfacility to the transfer position.

The automated overhead crane extends over the storage area, the loadingarea and the transition zone and is adapted to move cassettestherebetween.

According to another aspect, the facility can further comprise a manualoverhead receiving crane for moving packages from the line to theloading area and be characterized in that it is adapted to arrestmovement of the automated overhead crane in the loading area, if a humanis in the loading area.

According to another aspect, the facility can comprise a receiving areafor receiving packages from the line and the manual overhead crane canbe adapted to move packages from the receiving area to the loading area.

According to another aspect, the facility can further comprise: a bayfor receiving trucks; and a manual overhead shipping crane for movingpackages from the splitting subfacility to the bay.

According to another aspect, the facility can comprise: a shipping area;and a manual overhead shipping crane for moving packages from thesplitting subfacility to the shipping area.

According to another aspect, the line can be the cut-to-length line; andthe automated apparatus can be for moving the contents of a cassette inthe transfer position to the splitter subfacility and for moving apackage from the splitter subfacility to a cassette in the transferposition.

According to another aspect, each cassette can have a plurality ofapertures in the base thereof; and the transfer apparatus can comprise aconveyor and a lifter.

The conveyor has a plurality of rollers over which packages pass to andfrom the splitter subfacility. The lifter has a plurality of rollers,the rollers: having a lowered position whereat, when a cassette, loadedwith a package, is at the transfer position, the rollers are beneath thepackage; and having a raised position, whereat the rollers protrudethrough the apertures of the cassette to form an extension of theconveyor adapted to deliver packages to the conveyor and to receivepackages from the conveyor.

According to another aspect, each cassette can define a hollow and, ateach end of the hollow, an aperture, the aperture providing forcommunication between the rollers of the lifter when in the raisedposition and the rollers of the conveyor.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view of a facility according to an exemplary embodimentof the invention;

FIG. 2 is a view of the structure of FIG. 1 with portions removed;

FIG. 3 is a perspective view of the structure of encircled area 3 ofFIG. 1;

FIG. 4 is a perspective view of the structure of encircled area 4 ofFIG. 2, in a lowered position;

FIG. 5 is a view of the structure of FIG. 4 in a raised position;

FIG. 6 is a perspective view of a portion of the structure of encircledarea 6 of FIG. 1;

FIG. 7 is a view of the structure of FIG. 4 in use with the structure ofFIG. 3 and with a stack of sheet steel;

FIG. 8 is a view of the structure of FIG. 7 with the rollers raised;

FIG. 9 is a view similar to FIG. 8 with the stack partially ejected;

FIG. 10 is a view of an alternate embodiment of the structure of FIG. 3;

FIG. 11 is a view of an alternate embodiment of the structure of FIG. 6;

FIG. 12 is a view of an alternate embodiment of a stack, a lifter forthe stack and a splitter subfacility for splitting the stack; and

FIG. 13 is a view of a pallet used in the embodiment of FIG. 12.

DETAILED DESCRIPTION

A facility 20 constructed according to an exemplary embodiment of theinvention is shown in FIG. 1 and will be understood to include premisesand equipment as shown in FIG. 2 and cassettes as shown in FIG. 3

Premises

The premises will be seen to include a package receiving area 22, aloading area 24, a cassette storage area 26, a shipping area 28, atransition zone 30 having at least one transfer position 32 and a truckbay 34.

Equipment

The equipment will be seen to comprise a line 36, a splitter subfacility38, a manual overhead receiving crane 40, an automated storage crane 42,a manual overhead shipping crane 44 and an automated transfer apparatus46.

The line 36 is a cut-to-length line for producing packages in the formof stacks of steel sheets from coils of steel.

The splitter subfacility 38 in this embodiment is defined by a pair oflifters 48 and a pair of conveyors 50.

The lifter will be seen in isolation in FIG. 4 and FIG. 5 and will beunderstood to include a plurality of rollers 51, each roller beingadapted for driving rotational movement about its axis in fore and aftdirections and the plurality of rollers being adapted for movementbetween a lowered position as shown in FIG. 4 and a raised position asshown in FIG. 5. The conveyor (not shown in detail) will be understoodto function generally similarly to the lifter but with rollers fixed atan elevation intermediate the raised and lowered position of the lifter.

The manual overhead receiving crane extends from the receiving area 22to the loading area 24 as indicated by dotted line 40′.

The automated overhead receiving crane 42 extends over the cassettestorage 26 area, the transition zone 30 and the loading area 24 asindicated by dotted line 42′.

The manual overhead shipping crane 44 extends over the conveyors 50,50of the splitter subfacility 38, the shipping area 28 and the truck bay34, as indicated by dotted line 44′.

The automated transfer apparatus 46 includes a pair of lifters 48 asaforedescribed, a plurality of conveyors 50 as aforedescribed and a pairof turntables 52. The turntables (not shown in detail) will beunderstood to function generally similarly to the conveyors but theplurality of rollers are adapted for rotation about a vertical axis. Thelifters are each positioned at one of the transfer positions. One of theturntables is provided for each lifter. One of the conveyors is providedfor each lifter to couple said each lifter to the turntable providedtherefor. A further one of the conveyors extends between the turntablesand the final of the conveyors extends to the lifters of the splittersubfacility from one of the turntables.

Cassette

As seen in FIG. 3, the cassette 54 used in this embodiment: defines arectangular hollow 56; has four peripherally spaced lugs 58; has a base60 defining the bottom of the hollow in which a plurality of apertures62 are defined; has, at each end of the hollow, a rectangular aperture64; and has a plurality of receptacles 66 on the underside having ashape complementary with the lugs, to permit stacking.

Receiving

In operation, the cut-to-length line 36 delivers packages (stacks ofsheets) to the receiving area 22. In this embodiment, packages arebanded for transport in this area.

Loading

Banded packages are transported by overhead crane 44 to an emptycassette in the loading area 24. Banding is manually removed in thislocation.

Storage

The automated overhead crane 42 transfers empty cassettes to the loadingarea 24 and loaded cassettes to the storage area 26. Access control isprovided around the perimeter of the loading area; humans cannot enterthe loading area when the automated crane is overhead and the overheadcrane cannot overly the loading area when humans are therewithin. FIG. 6shows a loaded cassette in the carriage of the overhead crane.

Splitting

The contents of a cassette are split by delivery, by the automatedcrane, of the cassette to one of the transfer areas 32 in the transitionzone, as shown by FIG. 7. So positioned, the rollers of the lifter 48will be at the lowered position, beneath the package, and the rollers ofthe adjacent conveyor 50 will lead to the aperture 64 of the cassette.The rollers of lifter 48 are raised to an elevated position, as shown inFIG. 8, whereat the rollers protrude through the apertures 62 of thecassette to form an extension of the adjacent conveyor. Thereafter, therollers drive the package onto the adjacent conveyor, as indicated bythe sequence of FIGS. 8 and 9. The package is then passed by suchconveyor to the adjacent turntable 52, optionally through a furthercombination of conveyor 50 and turntable 52, and ultimately on to afinal conveyor 50 that communicates with the lifters 48 of the splittingsubfacility 38.

In this embodiment, splitting is done manually, by moving sheets fromthe package to a pallet. To minimize effort, this is done through a pairof adjacent lifters, to minimize the elevation difference between thesheet being removed from the package and the pallet onto which the sheetis to be loaded. Once the pallet has been suitably loaded, the pallet ispassed to the conveyors 50 within reach of the manual overhead crane,banded and removed by the overhead crane to a truck in the bay 34 or theshipping area 28, as appropriate. If only a portion of the cassette hasbeen loaded onto a pallet, the remainder is returned to a cassette,using a reversal of the process indicated above, and then returned tostorage. If the intent of the transfer was to fully empty the cassette,the cassette from which the material was removed is automatically storedby the overhead crane either within the transition zone or the storagearea.

It has been found, surprisingly, that if the line is operated with aview to maximum throughput, the production costs benefit outweigh theincremental costs of carrying the inventory and splitting theproduction, resultant from the relatively low amounts of floor spaceoccupied by the inventory and the relatively low cost at which it can beaccessed by virtue of the automated crane.

Whereas a specific embodiment has been hereinbefore described, it willbe evident that variations are possible.

For example, only, whereas the exemplary embodiment handles stacks ofsteel, the invention can be embodied for use with a slitter byproviding:

-   -   cassettes that handle multiple coils, as shown by FIG. 10;    -   overhead cranes adapted for carriage thereof as shown by FIG.        11;    -   a splitter subfacility adapted to receive a cassette, remove and        package for shipment at least some of such contents and        returning the cassette; and    -   automated transfer apparatus for moving a cassette in the        transfer position to the splitter subfacility and for moving a        cassette from the splitter subfacility to the transfer position.

As an alternative to the cassettes above, split coils could also bestored in stacks 70, as shown in FIG. 12, either in cassettes of thegeneral type shown in FIG. 3 or in isolation. Cassettes loaded withsplit coils could be moved with an overhead crane in the mannerindicated above and unloaded with the lifter indicated above. Stacks ofthe type shown in FIG. 12 could alternatively be moved with a four armpallet lifter 72, as indicated in FIG. 12, if positioned upon a palletsuch as that shown in FIG. 13. Splitting can be done with the four armpallet lifter or, one slit coil at a time, with a magnetic lifter 76, asshown in FIG. 12.

Other variations can also be provided, for example, secondary inspectioncould be provided by providing another access controlled area, similarto the loading area.

Accordingly the invention should be understood to be limited only by theaccompanying claims, purposively construed.

The invention claimed is:
 1. A facility comprising: a cut-to-length linefor producing packages, the packages being stacks of steel sheets; aplurality of stackable cassettes, each cassette having a plurality ofapertures in a base thereof and being adapted to receive at least onepackage; premises including a loading area in which packages from theline are loaded into cassettes, a storage area in which cassettes arestored and a transition zone including at least one transfer position; asplitter subfacility for: receiving a contents of a cassette, removingand packaging for shipment at least some of such contents and returningthe remainder; or receiving a cassette, removing and packaging forshipment at least some of such contents and returning the cassette;automated transfer apparatus for moving the contents of a cassettedisposed at the transfer position to the splitter subfacility and formoving a package from the splitter subfacility to a cassette in thetransfer position, the automated transfer apparatus comprising: aconveyor having a plurality of rollers over which packages pass to andfrom the splitter subfacility, and a lifter having a plurality ofrollers, the rollers having a lowered position whereat, when a cassette,loaded with a package, is at the transfer position, the rollers arebeneath the package, and having a raised position, whereat the rollersprotrude through the apertures of the cassette to form an extension ofthe conveyor adapted to deliver packages to the conveyor and to receivepackages from the conveyor; and an automated overhead crane extendingover the storage area, the loading area and the transition zone andadapted to move cassettes therebetween.
 2. A facility according to claim1, further comprising a manual overhead receiving crane for movingpackages from the line to the loading area and wherein the facility isadapted to arrest movement of the automated overhead crane in theloading area, if a human is in the loading area.
 3. A facility accordingto claim 2, further comprising a receiving area for receiving packagesfrom the line and wherein the manual overhead crane is adapted to movepackages from the receiving area to the loading area.
 4. A facilityaccording to claim 1, further comprising: a bay for receiving trucks;and a manual overhead shipping crane for moving packages from thesplitting subfacility to the bay.
 5. A facility according to claim 1,further comprising: a shipping area; and a manual overhead shippingcrane for moving packages from the splitting subfacility to the shippingarea.
 6. A facility according to claim 1, wherein each cassette definesa hollow and defines, at each end of the hollow, an aperture, theaperture providing for communication between the rollers of the lifterwhen in the raised position and the rollers of the conveyor.